3 HARDWARE AND WIRING - Grupo Feynsa V APPLICATION AND INSTALLATION MANUAL 3.3 ENGINE HARNESS The Engine Harness (EH) is installed at the factory and is delivered connected to all engine

Download 3 HARDWARE AND WIRING - Grupo Feynsa  V APPLICATION AND INSTALLATION MANUAL 3.3 ENGINE HARNESS The Engine Harness (EH) is installed at the factory and is delivered connected to all engine

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<ul><li><p>DDEC V APPLICATION AND INSTALLATION MANUAL</p><p>3 HARDWARE AND WIRING</p><p>Section Page</p><p>3.1 SUPPLIED HARDWARE ......................................................................... 3-3</p><p>3.2 ELECTRONIC CONTROL UNIT ............................................................. 3-5</p><p>3.3 ENGINE HARNESS ................................................................................ 3-11</p><p>3.4 VEHICLE INTERFACE HARNESS ......................................................... 3-15</p><p>3.5 POWER SUPPLY .................................................................................... 3-35</p><p>3.6 FUSES .................................................................................................... 3-37</p><p>3.7 CONNECTORS ....................................................................................... 3-39</p><p>3.8 WIRES AND WIRING ............................................................................. 3-55</p><p>3.9 CONDUIT AND LOOM ............................................................................ 3-81</p><p>3.10 TAPE AND TAPING ................................................................................ 3-83</p><p>3.11 SENSORS ............................................................................................... 3-85</p><p>3.12 THROTTLE DEVICES ............................................................................ 3-117</p><p>3.13 LIGHTS ................................................................................................... 3-121</p><p>All information subject to change without notice. (Rev. 09/05) 3-17SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>HARDWARE AND WIRING</p><p>THIS PAGE INTENTIONALLY LEFT BLANK</p><p>3-2 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>DDEC V APPLICATION AND INSTALLATION MANUAL</p><p>3.1 SUPPLIED HARDWARE</p><p>Original Equipment Manufacturer (OEM) supplied hardware and DDC supplied hardware isrequired to install DDEC V. The following sections list the minimum hardware required.</p><p>3.1.1 OEM-SUPPLIED HARDWARE</p><p>The minimum OEM-supplied hardware required is listed in Table 3-1.</p><p>Hardware Description</p><p>Vehicle Interface Harness (VIH)(refer to section 3.4)</p><p>Connects the vehicle functions and battery power (12/24volts) and ground to the ECU and includes fuse(s) or circuitbreaker(s). Also connects the ECU J1939 node to othervehicle systems.</p><p>Connector Shroud for VIH Connector(refer to section 3.2.1)</p><p>The shroud protects the connectors from dirt and directspray and routes the wires in the correct orientation.</p><p>Throttle Input Device(refer to section 3.12)</p><p>An Accelerator Pedal (AP) with an Idle Validation Switch(required), hand throttle, or alternative throttle device</p><p>Ignition Switch(refer to section 3.4.2) Switched 12 or 24 volt ignition source</p><p>Amber Warning Lamp (AWL)(refer to section 3.13.1) A panel-mounted amber indicator light.</p><p>Red Stop Lamp (RSL)(refer to section 3.13.2) A panel-mounted red indicator light.</p><p>Engine Coolant Level Sensor (ECL Sensor)(refer to section 3.11.20) A radiator top tank- or remote surge tank-mounted sensor</p><p>Diagnostic Connector, Cab (DCC)(refer to section 3.7.3) Cab-mounted diagnostic connector</p><p>Table 3-1 OEM-Supplied Hardware</p><p>3.1.2 DDC-SUPPLIED HARDWARE</p><p>The minimum DDC-supplied hardware required is listed in Table 3-2.</p><p>Hardware Description</p><p>Engine Harness(refer to section 3.3)</p><p>Factory installed harness that facilitates the receipt of input andoutput signals, controlling the fuel injection process and enginespeed. Harness is connected to DDC installed sensors, theinjection unit and the ECU(s).</p><p>Electronic Control Unit (ECU)Refer to section 3.2.</p><p>Engine mounted ECU provides control logic for overall enginemanagement.</p><p>Engine SensorsRefer to section 3.11.1. Various engine mounted sensors for engine control.</p><p>Turbo Compressor In Temperature SensorRefer to section 3.11.23.</p><p>Sensor to measure turbo compressor inlet temperature. MUSTbe installed by the OEM. Series 60 only.</p><p>Table 3-2 Minimum DDC-Supplied Hardware</p><p>All information subject to change without notice. (Rev. 09/05) 3-37SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>HARDWARE AND WIRING</p><p>THIS PAGE INTENTIONALLY LEFT BLANK</p><p>3-4 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>DDEC V APPLICATION AND INSTALLATION MANUAL</p><p>3.2 ELECTRONIC CONTROL UNIT</p><p>The engine-mounted Electronic Control Unit (ECU) (see Figure 3-1) includes control logic toprovide overall engine management. The ECU continuously performs self-diagnostic checksand monitors other system components. System diagnostic checks are made at ignition-on andcontinue throughout all engine-operating modes.</p><p>Figure 3-1 Electronic Control Unit</p><p>The DDEC V ECU has two 68-pin Tyco connectors - one for the engine and the other for thevehicle.</p><p>All information subject to change without notice. (Rev. 09/05) 3-57SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>HARDWARE AND WIRING</p><p>DDEC V supports three independent data links. There are two links on the Vehicle InterfaceHarness (VIH). One link is based on SAE J1708, and the second is SAE J1939. The other link,on the Engine Harness, is CAN based and will be used for proprietary communications such asmulti-ECU applications and DDC factory programming.</p><p>The following warning label is found on the ECU (see Figure 3-2).</p><p>Figure 3-2 ECU Warning Label</p><p>3-6 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>DDEC V APPLICATION AND INSTALLATION MANUAL</p><p>Connector shrouds protect the two 68-pin Tyco connectors (see Figure 3-3).</p><p>Figure 3-3 Electronic Control Unit with Connector ShroudsThe shrouds are fastened to the ECU studs with lock nuts.</p><p>See Figure 3-4 for the ECU outline and dimensions.</p><p>The DDEC V ECU has the same footprint as DDEC II, III, and IV.</p><p>Figure 3-4 Dimensions of Electronic Control Unit with Connector Shrouds</p><p>All information subject to change without notice. (Rev. 09/05) 3-77SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>HARDWARE AND WIRING</p><p>3.2.1 CONNECTOR SHROUD</p><p>The shroud is used to protect the connectors from dirt and direct spray and to route the wires inthe correct orientation. The shroud is designed for 25-30 mm conduit. The shroud is REQUIRED.</p><p>Different views of the connector shroud may be seen in the next illustration (see Figure 3-5).</p><p>Figure 3-5 Electronic Control Unit Connector Shroud</p><p>Two lock nuts are required to attach the shroud to the ECU studs. The torque specification forthe lock nuts is 30 in.lb (3.4 Nm).</p><p>3-8 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>DDEC V APPLICATION AND INSTALLATION MANUAL</p><p>3.2.2 ECU PART NUMBERS</p><p>Part number for the DDEC V ECU is listed in Table 3-3.</p><p>Description Part Number Voltage No. of CylindersDDEC V ECU 23530802 12/24 Volts 6</p><p>Table 3-3 ECU Part Numbers</p><p>The part numbers for the ECU connectors are listed in Table 3-4.</p><p>Description DDC Part Number Tyco Part NumberVehicle Interface HarnessConnector Assembly 23528252 776315-1</p><p>Engine Harness Connector Assembly 23528253 776315-2</p><p>Shroud 23532347 776501-1Shroud Lock Nuts</p><p>(M6x1.0 Nylon Insert Lock NutPlated with Yellow Zinc)</p><p>23533607 </p><p>ECU Stud 23533606 14 AWG Terminal (Large)</p><p>(Terminal only) 23528272 776492-1</p><p>18 AWG Terminal (Standard)(Terminal only) 23528271 776326-4</p><p>14 AWG Terminal (Large)(crimped with 12 in. wire) 23528255 </p><p>18 AWG Terminal (Standard)(crimped with 12 in. wire) 23528254 </p><p>Cavity Plug 23528274 776364</p><p>Table 3-4 ECU Connector Part Numbers</p><p>All information subject to change without notice. (Rev. 09/05) 3-97SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>HARDWARE AND WIRING</p><p>3.2.3 ENVIRONMENTAL CONDITIONS</p><p>The following environmental conditions must be considered.</p><p>Temperature</p><p>The ambient operating temperature range is -40F (-40C) minimum and 221F (105C)maximum.</p><p>Atmospheric Pressure</p><p>The engine-mounted ECU can withstand atmospheric pressures ranging from 62.0 to 120 kPaabsolute that result from altitude and weather changes in the operating and non-operatingconditions.</p><p>Water Intrusion</p><p>The ECU can be exposed to steam cleaning and pressure washing. Care should be taken not topressure spray the connectors.</p><p>3-10 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>DDEC V APPLICATION AND INSTALLATION MANUAL</p><p>3.3 ENGINE HARNESSThe Engine Harness (EH) is installed at the factory and is delivered connected to all enginesensors, the fuel injection system and the ECU.</p><p>3.3.1 EH CONNECTOR AND TYPICAL REQUIRED FUNCTIONSThe EH 68-pin Tyco connector pinout for the Series 60 is listed in Table 3-5 and Table 3-6.</p><p>Pin Wire Color Signal Type Function Connector</p><p>E-1 Blk PWM Output Low Side EGR Hydraulic ValveControlE-2 Wht Analog Input 1.5k Pull-up Air Temp</p><p>E-3 Analog Input 51k Pull-down Spare</p><p>E-4 Blk PWM Output Low Side VGT VPOD Control</p><p>E-5 Yel Analog Input 1.5k Pull-up Coolant Temp</p><p>E-6 Analog Input 51k Pull-down Spare</p><p>E-7 Tan Analog Input 1.5k Pull-up Oil Temp</p><p>E-8 PWM Output Low Side Spare</p><p>E-9 Orn Analog Input 1.5k Pull-up Fuel Temp</p><p>E-10 Analog Input 1.5k Pull-up EGR Temp</p><p>E-11 PWM Output Low Side Spare</p><p>E-12 Gra Sensor Supply #3 Sensor Supply</p><p>E-13 Digital Output Low Side Spare</p><p>E-14 Blk Sensor Return #4 Sensor Return</p><p>E-15 Blk Sensor Return #3 Sensor Return</p><p>E-16 Yel Analog Input 51k Pull-down Fuel Restriction (MAS)</p><p>E-17 Ppl TRS (CKP) (-) TRS (CKP) (-)</p><p>E-18 Dk Grn TRS (CKP) (+) TRS (CKP) (+)</p><p>E-19 Lt Blu SRS (CMP) (+) SRS (CMP) (+)</p><p>E-20 Wht SRS (CMP) (-) SRS (CMP) (-)</p><p>E-21 Dk Grn Analog Input 51k Pull-down Oil Level (MAS)</p><p>E-22 Dk Blu Analog Input 1.5k Pull-up Turbo Compressor OutTempE-23 Analog Input 1.5k Pull-up Spare</p><p>E-24 Analog Input 51k Pull-down Spare</p><p>E-25 Analog Input 51k Pull-down Spare</p><p>E-26 Gra Sensor Supply #4 Sensor Supply</p><p>E-27 Analog Input 1.5k Pull-up Spare</p><p>E-28 Ground Pin Spare</p><p>E-29 Ground Pin Spare</p><p>E-30 Ground Pin Spare</p><p>E-31 Brn Analog Input 51k Pull-down Oil Pressure</p><p>E-32 Frequency Input (+) Aux 3 Spare</p><p>Shroud Side of Connector</p><p>Table 3-5 Series 60 Engine Harness Connector - Pins E-1 Through E-32</p><p>All information subject to change without notice. (Rev. 09/05) 3-117SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>HARDWARE AND WIRING</p><p>Pin Wire Color Signal Type Function ConnectorE-33 Frequency Input (-) Aux3 Spare</p><p>E-34 Brn Frequency Input (-) Aux2 Turbo Speed Sensor (+)</p><p>E-35 Blk Frequency Input (+) Aux2 Turbo Speed Sensor (-)</p><p>E-36 Analog Input 1.5k Pull-up Spare</p><p>E-37 Pnk Analog Input 51k Pull-down Barometric Pressure</p><p>E-38 Analog Input 51k Pull-down EGR Delta Pressure</p><p>E-39 Lt Grn Analog Input 51k Pull-down Turbo Boost</p><p>E-40 Dk Blue CAN2 (+) CAN2 (+)</p><p>E-41 Analog Input 51k Pull-down Spare</p><p>E-42 Bk Ground Pin VGT VPOD Gnd</p><p>E-43 Bk Ground Pin Spare</p><p>E-44 Ground Pin Spare</p><p>E-45 Ground Pin Spare</p><p>E-46 Lt Grn Digital Output High Side Switched Battery (+) VGTE-47 Digital Output High Side Spare</p><p>E-48 Red Digital Output High Side Jake Med/High</p><p>E-49 Orn Digital Output High Side Jake Low</p><p>E-50 Digital Output High Side Spare</p><p>E-51 Yel Digital Output High Side Switch Battery (+) EGR</p><p>E-52 Red Digital Output High Side Spare</p><p>E-53 Digital Output High Side Spare</p><p>E-54 Pnk CAN2 (-) CAN2 (-)</p><p>E-55 Blk CAN2S CAN2 Shield</p><p>E-56 Analog Input 51k Pull-down Spare</p><p>E-57 Analog Input HWOLS No Connection</p><p>E-58 Analog Input 1.5k Pull-up Spare</p><p>E-59 RTC BATT+ External RTC Battery (+)</p><p>E-60 Ground Pin Spare</p><p>E-61 Wht Injector High Common S60 Common Cyl #1,2,3</p><p>E-62 Wht Injector High Common S60 Common Cyl #4,5, 6</p><p>E-63 Wht Injector A LO1 S60 Cylinder #1</p><p>E-64 Wht Injector A LO2 S60 Cylinder #3</p><p>E-65 Wht Injector A LO3 S60 Cylinder #2</p><p>E-66 Wht Injector B LO1 S60 Cylinder #5</p><p>E-67 Wht Injector B LO2 S60 Cylinder #6</p><p>E-68 Wht Injector B LO3 S60 Cylinder #4</p><p>Shroud Side of Connector</p><p>Table 3-6 Series 60 Engine Harness Connector - Pins E-33 Through E-68</p><p>3-12 All information subject to change without notice. (Rev. 09/05)7SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>DDEC V APPLICATION AND INSTALLATION MANUAL</p><p>The EH 68-pin Tyco connector pinout for Series 60 non-road equipment is listed in Table 3-7and Table 3-8.</p><p>Pin Wire Color Signal Type Function ConnectorE-1 PWM Output Low Side Spare</p><p>E-2 Wht Analog Input 1.5k Pull-up Air Temp</p><p>E-3 Analog Input 51k Pull-down Spare</p><p>E-4 PWM Output Low Side Spare</p><p>E-5 Yel Analog Input 1.5k Pull-up Coolant Temp</p><p>E-6 Analog Input 51k Pull-down Spare</p><p>E-7 Tan Analog Input 1.5k Pull-up Oil Temp</p><p>E-8 PWM Output Low Side Spare</p><p>E-9 Orn Analog Input 1.5k Pull-up Fuel Temp</p><p>E-10 Analog Input 1.5k Pull-up Spare</p><p>E-11 PWM Output Low Side Spare</p><p>E-12 Gra Sensor Supply #3 Sensor Supply</p><p>E-13 Digital Output Low Side Spare</p><p>E-14 Blk Sensor Return #4 Sensor Return</p><p>E-15 Blk Sensor Return #3 Sensor Return</p><p>E-16 Yel Analog Input 51k Pull-down Spare</p><p>E-17 Ppl TRS (CKP) (-) TRS (CKP) (-)</p><p>E-18 Dk Grn TRS (CKP) (+) TRS (CKP) (+)</p><p>E-19 Lt Blu SRS (CMP) (+) SRS (CMP) (+)</p><p>E-20 Wht SRS (CMP) (-) SRS (CMP) (-)</p><p>E-21 Dk Grn Analog Input 51k Pull-down Spare</p><p>E-22 Analog Input 1.5k Pull-up Spare</p><p>E-23 Analog Input 1.5k Pull-up Spare</p><p>E-24 Analog Input 51k Pull-down Spare</p><p>E-25 Analog Input 51k Pull-down Spare</p><p>E-26 Gra Sensor Supply #4 Sensor Supply</p><p>E-27 Analog Input 1.5k Pull-up Spare</p><p>E-28 Ground Pin Spare</p><p>E-29 Ground Pin Spare</p><p>E-30 Ground Pin Spare</p><p>E-31 Brn Analog Input 51k Pull-down Oil Pressure</p><p>E-32 Frequency Input (+) Aux 3 Spare</p><p>Shroud Side of Connector</p><p>Table 3-7 Series 60 Engine Harness Connector for Non-Road Equipment - PinsE-1 Through E-32</p><p>All information subject to change without notice. (Rev. 09/05) 3-137SA821 0509 Copyright 2005 DETROIT DIESEL CORPORATION</p></li><li><p>HARDWARE AND WIRING</p><p>Pin Wire Color Signal Type Function ConnectorE-33 Frequency Input (-) Aux3 Spare</p><p>E-34 Frequency Input (-) Aux2 Spare</p><p>E-35 Frequency Input (+) Aux2 Spare</p><p>E-36 Analog Input 1.5k Pull-up Spare</p><p>E-37 Pnk Analog Input 51k Pull-down Spare</p><p>E-38 Analog Input 51k Pull-down Spare</p><p>E-39 Lt Grn Analog Input 51k Pull-down Turbo Boost</p><p>E-40 Dk Blue CAN2 (+) CAN2 (+)</p><p>E-41 Analog Input 51k Pull-down Spare</p><p>E-42 Ground Pin Spare</p><p>E-43 Bk Ground Pin Spare</p><p>E-44 Ground Pin Spare</p><p>E-45 Ground Pin Spare</p><p>E-46 Digital Output High Side Spare</p><p>E-47 Digital Output High Side Spare</p><p>E-48 Red Digital Output High Side Jake Med/High</p><p>E-49 Orn Digital Output High Side Jake Low</p><p>E-50 Digital Output High Side Spare</p><p>E-51 Yel Digital Output High Side Spare</p><p>E-52 Red Digital Output High Side Spare</p><p>E-53 Digital Output High Side Spare</p><p>E-54 Pnk CAN2 (-) CAN2 (-)</p><p>E-55 Blk CAN2S CAN2 Shield</p><p>E-56 Analog Input 51k Pull-down Spare</p><p>E-57 Analog Input HWOLS No Connection</p><p>E-58 Analog Input 1.5k Pull-up Spare</p><p>E-59 RTC BATT+ External RTC Battery (+)</p><p>E-60 Ground Pin Spare</p><p>E-61 Wht Injector High Common S60 Common Cyl #1,2,3</p><p>E-62 Wht Injector High Common S60 Common Cyl #4,5, 6</p><p>E-63 Wht Injector A LO1 S60 Cylinder #1</p><p>E-64 Wht Injector A LO2 S60 Cylinder #3</p><p>E-65 Wht Injector A LO3 S60 Cylinder #2</p><p>E-66 Wht Injector B LO1 S60 Cylinder #5</p><p>E-67 Wht...</p></li></ul>